Methods of manufacturing tamper-resistant and tamper evident containers

ABSTRACT

A tamper-resistant container with tamper-evident features which includes a cover portion defining a peripheral flange, a base portion defining an upper peripheral edge, and a hinge joining the cover portion with the base portion. The upper peripheral edge includes an upwardly projecting bead extending substantially about the perimeter of the base portion that is configured to render the peripheral flange of the cover portion relatively inaccessible when the container is closed. The hinge includes a frangible portion for facilitating the removal of the cover portion from the base portion to open the container.

CROSS-REFERENCE TO RELATED APPLICATION(S)

The subject application is a division of Ser. No. 11/483,900 filed Jul.10, 2006, which is a continuation in part of U.S. patent applicationSer. No. 11/065,681, filed Feb. 24, 2005, now U.S. Pat. No. 7,073,680,which is a continuation in part of U.S. patent application Ser. No.10/895,687 filed Jul. 21, 2004, which claims the benefit of priority toU.S. Provisional Patent Application No. 60/489,093 filed Jul. 21, 2003,the disclosure of each being incorporated by reference herein in itsentirety.

BACKGROUND OF THE INVENTION

1. Field of the Invention

The subject invention is directed to containers and packaging, and moreparticularly, to containers and packaging that incorporatetamper-resistant and tamper-evident features.

2. Background of the Related Art

Disposable containers for packaging, distributing, displaying orotherwise housing consumer items, especially perishable foods, arebecoming increasingly important. Historically, perishable products hadto be brought to market and sold quickly before exposure to theatmosphere caused the products to lose their freshness.

The advent of plastics resulted in many products being wrapped orpackaged in plastic, both in the form of flexible plastic bags and solidplastic containers. The use of plastics in the modern-day conveniencefood industry has significantly improved the “shelf life” of perishableproducts, allowing both merchants and their customers to store theproducts for longer periods of time, resulting in substantial savings.

It has been found that consumers like recloseable packages, particularlyfor comestible products, especially in circumstances where more than oneserving of a comestible product is contained therein, in order to reducedrying out or other deterioration of the comestible food product. Inaddition, consumers prefer to visually inspect the food product withinsuch containers prior to purchase. Thus, fabricating containers fromclear see-through plastics is desirable. For example, packaging providedfor bakery goods has often been in the form of clear, plastic clamshellpackaging, because, among other things, such clear, plastic clamshellpackaging, provides a baked-on-the-premises image which groceryretailers have found to be especially appealing to consumers.

Typically, plastic containers will include a fairly rigid lid and base,although they may be subject to some amount of flexure. The lid providedmust be capable of properly and effectively sealing the container, yetthe container must be constructed so that the lid is relatively easy toremove, and even replace, since it is expected that the container andlid would normally be reused.

In addition to the aforementioned consumer design preferences, it isdesirable to fabricate containers that include features which eitherdeter unauthorized tampering or clearly indicate whether unauthorizedtampering has occurred, or both. These tamper-resistant/evident featurestypically include structural elements which, when the container istampered with or opened without authorization, enable the consumer toeasily visually recognize such tampering so that the product can then berejected. Such tamper-resistant/evident elements are important for,among other things, deterring theft and preventing the loss of productand income for the seller, as well as instilling consumer confidence inthe integrity of the contents within the container and confidence in theability of the seller and/or manufacturer to provide and maintainquality goods.

Thus, there is a compelling interest in the development of containershaving consumer-preferable design elements, such as recloseabilityfeatures which are reliable and easy to operate, along withtamper-resistant/evident features that deter tampering and clearlyindicate whether tampering has occurred, and which are also reliablewithout being burdensome to the legitimate consumer. Accordingly, thepresent invention is directed to a container that meets these needs.

SUMMARY OF THE DISCLOSURE

The present invention meets the aforementioned needs, while alsoimproving upon and solving problems associated with previous containersby providing, among other things, a tamper-resistant container withtamper-evident features (also referred to herein as a“tamper-resistant/evident container”) that includes a cover portiondefining an outwardly extending peripheral flange and a base portiondefining an upper peripheral edge. The upper peripheral edge of the baseportion includes, at least in part, an upwardly projecting beadextending substantially about the perimeter of the base portion. Thisbead is configured and dimensioned to render the outwardly extendingflange of the cover portion relatively inaccessible when the containeris closed.

The container can further include a hinge joining the outwardlyextending flange of the cover portion with the base portion. The hingepreferably includes a frangible portion, which upon severing,facilitates removal of the cover portion from the base portion. In oneembodiment, the frangible section of the hinge is delimited at least inpart by a pair of parallel score lines or a plurality of spaced apartnotches, depressions or nicks associated with the score lines.

In another embodiment, the container includes a skirt which dependsdownwardly from the upper peripheral edge of the base portion.Preferably, the hinge extends from the lower edge of the skirt to theoutwardly extending flange of the cover portion.

These and other aspects of the present invention will become morereadily apparent to those having ordinary skill in the art from thefollowing detailed description of the invention taken in conjunctionwith the drawings.

BRIEF DESCRIPTION OF THE FIGURES

So that those having ordinary skill in the art to which the subjectinvention pertains will more readily understand how to make and use thetamper-resistant/evident package disclosed herein, embodiments thereofwill be described in detail below with reference to the drawings,wherein:

FIG. 1 is a perspective view of a tamper-resistant/evident containerconstructed in accordance with the present invention in an exemplarycircular configuration having a base portion and cover portion connectedto each other by a hinge having a frangible section;

FIG. 2 is a side view of the container shown in FIG. 1, illustrating inparticular the hinge having a frangible section or strip, and a suitablelocation for indicia to be printed thereon;

FIG. 3 is a partial top view of the container shown in FIG. 1,illustrating in particular the hinge having a frangible section or stripand projection associated therewith that extends beyond the upwardlyprojecting bead associated with the upper peripheral surface of the baseportion;

FIG. 4 is a partial cross sectional view of the container shown in FIG.1, taken along line 4-4 of FIG. 2, illustrating in particular the hingehaving a frangible section and upper and lower projections or armsextending from the cover portion and base portion of the container;

FIG. 5 is a partial cross sectional view of the container shown in FIG.1, taken along line 5-5 of FIG. 8, illustrating in particular theconfiguration of the base portion and the structural elements thatfacilitate a releasable/recloseable engagement with the cover portion;

FIG. 6 is a partial cross sectional view of the container shown in FIG.1, taken along line 6-6 of FIG. 8, illustrating in particular theconfiguration of the cover portion and the structural elements thatfacilitate a releasable/recloseable engagement with the base portion;

FIG. 7 is a partial cross sectional view of the container shown in FIG.1, taken along line 7-7 of FIG. 3, illustrating in particular theconfiguration of the base portion and cover portion when the containeris closed and including the structural elements that facilitate areleasable/recloseable engagement between the base and cover portions;

FIG. 8 is an exploded perspective view of the container shown in FIG. 1,illustrating in particular the operative association between the coverportion, base portion and frangible section;

FIG. 9 is a side view of the container shown in FIG. 1, in which thefrangible section has been removed, illustrating the manner in which thecover portion is separated from the base portion and the upper and lowerprojections or arms associated with the cover and base portions,respectively;

FIG. 10 is a partial perspective view of the container shown in FIG. 1,illustrating in particular the manner in which the upwardly projectingbead on the base portion physically prevents access to the outer edge ofthe cover portion, making it difficult to separate the cover portionfrom the base portion;

FIG. 11 is a partial perspective view of the container shown in FIG. 1,illustrating in particular the manner in which the frangible section canbe removed from the hinge;

FIG. 12 is a partial perspective view of the container shown in FIG. 1,illustrating in particular the upper and lower projections formed byremoval of the frangible section and the manner in which the upper andlower projections facilitate separation of the cover portion from thebase portion;

FIG. 13 is a side view of a two blade knife that can be used to form thefrangible section of a container constructed in accordance with thepresent invention;

FIG. 14 is a front plan view of a first blade of the two blade knife ofFIG. 13, illustrating the position of the nicks and cutting surfacesthat can form a first score line of a frangible section of a containerconstructed in accordance with the present invention;

FIG. 15 is a front plan view of a second blade of the two blade knife ofFIG. 13, illustrating the position of the nicks, cutting surfaces andoffset that can form a second score line of a frangible section of acontainer constructed in accordance with the present invention;

FIG. 16 is perspective view of a tamper-resistant/evident containerconstructed in accordance with the present invention in an exemplaryrectangular configuration having a base portion and cover portionconnected to each other by a hinge having a frangible section;

FIG. 17 is a side view of the container shown in FIG. 16, illustratingin particular the hinge having a frangible section or strip, patternedsections on opposing ends thereof, and tabs defined by the frangiblesection score line;

FIG. 18 is a partial cross sectional view of the container shown in FIG.16, taken along line 18-18 of FIG. 17, illustrating in particular theconfiguration of the hinge, upper and lower projections and frangiblesection;

FIG. 19 is a partial cross sectional view of the container shown in FIG.16, taken along line 19-19 of FIG. 17, illustrating in particular theconfiguration of the hinge, upper and lower projections, frangiblesection, and score line defining a tab associated with the lowerprojection;

FIG. 20 is a partial cross sectional view of the container shown in FIG.16, illustrating in particular the manner in which the cover portion isclosed on the base portion;

FIG. 21 is a partial perspective view of the container shown in FIG. 16,illustrating in particular the manner in which the frangible section isremoved from the hinge;

FIGS. 22-23 are partial perspective views of the container shown in FIG.1, illustrating in particular the manner in which the separation of thecover portion from the base portion is facilitated by clasping thepatterned section disposed on the upper projection or arm associatedwith the cover portion which is formed upon removal of the frangiblesection;

FIG. 24 is a perspective view of another embodiment of atamper-resistant/evident container constructed in accordance with thepresent invention having an additional engagement mechanism and supportstructure for providing enhanced structural integrity and furthersecuring the base portion and cover portion, among other things; and

FIG. 25 is another perspective view of the tamper-resistant/evidentcontainer shown in FIG. 24.

FIG. 26 is a perspective view of another embodiment of atamper-resistant/evident container similar to that depicted in FIGS.24-25, but including a further variation of a pattern of reinforcingribs.

FIGS. 27-28 are perspective views of another embodiment of atamper-resistant/evident container made in accordance with theinvention. FIG. 27 is a view of the interior of such an open container,and FIG. 28 is a view of the exterior of the container.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

The advantages of a tamper-resistant/evident container constructed inaccordance with the present invention will become more readily apparentto those having ordinary skill in the art from the following detaileddescription of certain preferred and exemplary embodiments taken inconjunction with the drawings which set forth representative embodimentsthereof, but are not intended to limit the scope of the presentinvention.

Unless otherwise apparent, or stated, directional references, such as“right,” “left,” “upper,” “lower,” “outward,” “inward,” etc., areintended to be relative to the orientation of a particular embodiment ofthe invention as shown in the first numbered view of that embodiment. Inaddition, a given reference numeral indicates the same or similarstructure when it appears in different figures and like referencenumerals identify similar structural elements and/or features of thesubject invention.

In accordance with an exemplary embodiment of the subject inventionillustrated in FIGS. 1 and 2, the container 10 includes a generallycircular cover portion 12 and a generally bowl-shaped base portion 14joined together by a hinge 16. Hinge 16 includes a tamper-evidentfrangible section or pull strip 18, which, upon its removal, severs theintegral connection between cover portion 12 and base portion 14.

In use, container 10 would be filled with the contents for whichconsumer protection is desired and cover portion 12 would be engagedwith base portion 14. In accordance with the present invention, coverportion 12 and base portion 14 may include structural features thatfacilitate the formation of a non-permanent engagement between coverportion 12 to base portion 14.

In this embodiment, the non-permanent engagement between cover portion12 and base portion 14 is facilitated by, among other things, aperipheral locking shoulder 20 and an radially inward circumferentialgroove 22 formed below an outwardly extending peripheral flange 24 oncover portion 12, which can be seated within a corresponding matingcircumferential recess 26 on base portion 14. Circumferential recess 26on base portion 14 is formed below an upper peripheral rim 28 andincludes a radially inward projecting rib 30 and a radially inwardlyextending rim 32.

When cover portion 12 is closed on base portion 14, projecting rib 30mates with circumferential groove 22 on cover portion 12 and extendingrim 32 mates with locking shoulder 20 on cover portion 12. In addition,outwardly extending peripheral flange 24 on cover portion 12 abuts upperperipheral rim 28 on base portion 14.

Container 10 incorporates features which are intended to prevent anddeter opening container 10 without first removing frangible strip 18from hinge 16. In this embodiment, container 10 includes an upwardlyprojecting bead 34 on base portion 14 that extends substantially aboutthe perimeter of peripheral rim 28 and is positioned to surround theouter edge of flange 24 of cover portion 12 when container 10 is closed.The position and upward extension of bead 34 is configured to hinder therelatively easy method of removing a cover from conventional containersthat may resemble or have characteristics in common with container 10.As can be best viewed in FIG. 10, bead 34 physically blocks access tothe edge of peripheral flange 24 on cover portion 12 from fingers or anyother object that might normally be used for leverage to pry coverportion 12 from base portion 14.

Hinge 16 includes an upper outwardly projecting arm 36 connected to baseportion 14, and a similar lower outwardly projecting arm 38, which isconnected to cover portion 12. In particular, upper arm 36 is connectedwith a skirt 40 that projects downward from upper peripheral rim 28 andradially outward with respect to base portion 14. Lower arm 38 isconnected with the peripheral flange 24. Upper and lower arms 36 and 38are joined together by a common attachment to frangible strip 18 to formhinge 16.

Preferably, frangible strip 18 is delimited at least in part by a pairof parallel score lines 42 a, 42 b or areas that have been weakened orstressed during the forming process. Frangible strip 18 may be furtherdelimited by a plurality of spaced apart areas in which material hasbeen removed associated with the score lines, by a plurality of spacedapart depressions associated with the score lines, or by perforationlines. The width and depth of the areas and/or depressions can vary tocontrol the tear resistance offered by frangible strip 18.Alternatively, the integral hinge 16 could be formed with a single scoreline or perforation line, rather than a pair of score lines. In thisinstance, the single score line could be severed to create a pair ofprojections which would be used to open the container.

In this embodiment, strip 18 includes laterally opposed grasping tabs 44a and 44 b to provide a convenient location for gripping strip 18.Preferably, instructional indicia is imprinted on strip 18 to facilitateits removal from hinge 16 and/or consumer understanding of thesignificance of its removal as it relates to product tampering. Strip 18and/or the instructional indicia preferably thereon can be colored orembossed, or otherwise fabricated to direct attention thereto.

As can be best viewed in FIGS. 11 and 12, detaching frangible strip 18from hinge 16 of container 10 leaves behind upper and lower arms 36 and38 on cover portion 12 and base portion 14, respectively. Upper andlower arms 36 and 38 extend outwardly from container 10 and can be usedto facilitate removal of cover portion 12 from base portion 14, oncestrip 18 has been removed, by applying sufficient opposing force todisengage locking shoulder 20 from within circumferential recess 26.

The presence of bead 34 prevents unauthorized access to the contents ofcontainer 10 by making it difficult to pull cover portion 12 from baseportion 14. If access to container 10 is desired, strip 18 must beremoved so that upper and lower arms 36 and 38 are free to be used toleverage cover portion 12 from base portion 14. Cover portion 12 may bereplaced on base portion 14 after container 10 is opened. Strip 18,however, once removed, is not replaceable. Thus, removal of strip 18functions as a clear indicator of possible tampering, in that if strip18 is partially or fully removed prior to purchase, it is readilyapparent to a consumer that someone may have already gained access tothe contents of container 10.

FIGS. 13-15 illustrate an exemplary configuration for a double scoringblade having blades 46 a, 46 b, which can be used in a punch presssystem or the like to form score lines 42 a, 42 b in accordance with oneembodiment of the present invention. Various dimensions of blades 46 a,46 b are also provided herein as a non-limiting example.

The lateral separation L1 between blades 46 a, 46 b is in thisembodiment about 0.36 inches. The length L2 of blades 46 a, 46 b isabout 2.25 inches. Blades 46 a, 46 b include an offset recessed portion48 with a series of substantially similar nicks 50 cut therein betweencutting edges 52. The width L3 of cutting edges 52 is preferably 0.36inches. Preferably, the offset L4 between recessed portion 48 andcutting edges 52 is approximately 0.001 inches.

In this embodiment, blade 46 a includes seven (7) nicks 50 while blade46 b includes eight (8) nicks 50. The nicks 50 on blade 46 a are offsetwith respect to the nicks 50 on blade 46 b, which results in a desirablezipper-like effect when removing strip 18. Preferably, nicks 50 aretriangular shaped, about 0.010 inches deep and about 0.020 inches wide,and define an approximately 90 degree angle at its deepest convergencepoint 54. The length L5 between nicks 50, as measured between therespective convergence points 54 of adjacent nicks 50, is approximately0.252 inches. The length L6 between the respective convergence points 54of adjacent offset nicks 50 on blade 46 b is about 0.126 inches. Thelength L7 of blades 46 a, 46 b is about 0.1 inches, and each blade edgedefines an angle of about 45 degrees.

It should be readily understood that a container constructed inaccordance with the present invention, which is preferably a plasticcontainer used for carrying edible items, can be manufactured in avariety of shapes and sizes, and can be formed from resins or plasticmaterials such as polyethylene, polypropylene, polyvinyl chloride orpolyethylene terephthalate (“PETE”), as well as other suitable materialsor combinations thereof. The forming process can also vary to includemethods such as thermo-forming, injection molding or blow molding. Thecontainer can be transparent or translucent, and may be colored ineither instance. Also, vents can be provided in the container to promoteairflow therethrough, if appropriate based on the intended contents ofthe container.

Preferably, container 10 is formed from a roll of PETE subjected to avacuum and pressure mold with plug assist. During manufacture, blades 46a, 46 b of FIGS. 13-15 are preferably applied to a newly formedcontainer 10 to impart score lines 42 a, 42 b thereon. Cutting edges 52cut substantially through the material used to make container 10.Preferably, the configuration of blades 46 a, 46 b are designed so thata desirable amount of force is necessary to remove strip 18, asdetermined by consumer trials for example. Those skilled in the art willreadily appreciate that the configuration of blades 46 a, 46 b can beadjusted for a variety of reasons, and the above dimensions areexemplary of one embodiment of the present invention.

For example, various other methods can be employed to form frangiblestrip 18 of hinge 16. For example, score lines, nicks or penetrationscan be created with the molding tool itself during the forming step.Alternatively, a high die forming process can be employed where, afterthe forming step, the container is indexed to a trim station, where oneor more knives liberate the container and create the score lines orperforations. Also, an intermittent cutter can be employed between theforming step or the trim step, a progressive punch and die operation canbe employed, or a numerically controlled laser can be employed to createthe nicks. It is also envisioned that electro-mechanical, ultra-sonic orhydrodynamic systems can be employed in the forming process.

Container 10 could also be formed with locking arrangements known in theart other than the tamper-resistant/evident closure of the subjectinvention, such as traditional male and female locking features.

Referring to FIGS. 16-23, there is illustrated anothertamper-resistant/evident container constructed in accordance with apreferred embodiment of the subject invention and designated generallyby reference numeral 110. Container 110 is similar to container 10described above except that container 110 is rectangular inconfiguration rather than circular. Container 110 thus includes a baseportion 114 and a cover portion 112 joined together by an integrallyformed hinge 116 that defines a tamper-evident frangible pull strip 118,which must be removed before cover portion 112 can be readily removedfrom base portion 114.

Container 110 includes embossed or raised patterned sections 156 a and156 b on opposing tabs 144 a and 144 b of strip 118, respectively, tofacilitate removal of strip 118. Patterned sections 158 a and 158 b arealso disposed on opposing sides of upper arm 136 to facilitateseparation of cover portion 112 from base portion 114. Instructionalindicia can be imprinted on upper arm 136 between patterned sections 158a and 158 b.

In this embodiment, score line 142 b is situated on hinge 116 to definetwo tabs 160 a and 160 b which are connected with lower arm 138. Tabs160 a, 160 b remain in place on hinge 116 until strip 118 is removed, ascan be best viewed in FIGS. 21-23. Tabs 160 a, 160 b extend from lowerarm 138 to further facilitate gripping lower arm 138 and separation ofcover portion 112 from base portion 114.

FIGS. 24-26 illustrate other tamper-resistant/evident containersconstructed in accordance with a preferred embodiment of the subjectinvention and designated generally by reference numeral 210. Container210 is rectangular in shape, but may be formed in other shapes, and hassimilar features to containers 10 and 110 described above. Container 210includes, among other things, a base portion 214 and a cover portion 212joined together by an integrally formed hinge 216 that defines atamper-evident frangible pull strip 218, which must be removed beforecover portion 212 can be readily removed from base portion 214. Anupwardly projecting bead 234 is disposed on peripheral rim 222 of baseportion 214. Bead 234 is positioned to substantially surround the outeredge of flange 224 of cover portion 212 when container 210 is closed,thus physically blocking access by fingers or any other object thatcould be applied to the edge of peripheral flange 224 and rim 222 forleverage while attempting to pry cover portion 212 from base portion214.

In the embodiments of FIGS. 24-25 a plurality of supporting ribs 262a-f, each extending from about the enclosed bottom of base portion 214to about extending rim 232 are positioned at the four corners (ribs 262a-d, respectively) of base portion 214 and the midpoints on hinge sidewall 264 (rib 262 e) and opposing side wall 266 (rib 262 f) of baseportion 214 to provide enhanced structural integrity. Supporting ribs262 a-f generally consist of multiple elongated, arcuate portions, eachhaving a curved latitudinal cross-sectional profile, positionedadjacently with respect to one another.

In the embodiment disclosed in FIG. 26, a multiplicity of ribs 262 areprovided distributed about the bottom of base portion 214 as well asabout the peripheral wall 214 a of base portion 214. Applicants havediscovered that the disclosed arrangement of ribs 262 about base portion214 provides particularly advantageous performance. Over two dozencontainers were tested having various rib patterns. However, thecontainer disclosed in FIG. 26 exhibited the most superior performance.By way of illustration only, the container depicted in FIGS. 24-25,without the rib pattern of the container in FIG. 26 may be made, forexample, from a thermoformable material such as polyethyleneterephthalate sheet in a thickness range from about 12 mils to about 40mils, and preferably from about 14 mils to about 25 mils, depending onthe size of the container. For example, it may be desirable to form asmaller container from a thinner gage material than a larger container.

It has been discovered that the container depicted in FIG. 26 can bemade from a substantially thinner gage of sheet material than thatdepicted in FIG. 25. A 32 ounce container as depicted in FIG. 25 made ofpolyethylene terephtalate, for example, can be made from a 25 mil sheet.In contrast, an even stronger container as depicted in FIG. 26 can bemade from a 22 mil sheet. It is further believed that such a containercould be made of a 20 mil sheet of polyethylene terephtalate. Thisaccordingly may result in a 20% material savings, which can result insignificant cost reduction for making a container of a given size.

As further disclosed in these embodiments, a circumferential engagementsealing interface between cover portion 212 and base portion 214 isdefined in part by a plurality of outwardly bowed arcuate portions 290.As depicted, outwardly bowed arcuate portions 290 are connected byrounded corner portions 292.

Container 210 may also include an additional independent, engagingmechanism that provides even further structural integrity, enhancessecurity by urging flange 224 to remain in position against peripheralrim 222, and facilitates the reattachment of cover portion 212 to baseportion 214, among other things. As depicted in FIGS. 24 and 25, forexample, male engaging member 268 projects upwardly from supporting rib262 f on side wall 266 which is received by a correspondingly sizedfemale engaging member 270 defined on cover portion 212.

Thus, when container 210 is closed, male engaging member 268 on baseportion 214 and female engaging member 270 on cover portion 212 form anengagement which further secures base portion 214 to cover portion 212.In addition to urging flange 224 against rim 222, the aforementionedfeatures increase the amount of force that would be necessary to prycover portion 212 from base portion 214 in an unauthorized manner (i.e.,without removal of strip 218).

Also, the aforementioned engagement facilitates the reattachment ofcover portion 212 with base portion 214 after container 210 is openedlegitimately by a consumer. Container 210 can be reclosed after purchaseby urging cover portion 212 onto base portion 214, and in particular,this can be accomplished by pressing on the corners of cover portion212, as indicated by instructional indicia printed in the outer cornerareas of cover portion 212 in this embodiment. In reclosing container210, the initial engagement of male member 268 with female member 270facilitates the subsequent step of applying pressure on the corners ofcover portion 212, making it easier to reattach cover portion 212 tobase portion 214. It should be readily apparent to those skilled in theart that other engagement mechanisms, devices, engagements and containerdesigns, and combinations thereof, could be incorporated in anyembodiment in accordance with the present invention.

FIGS. 27-28 illustrate another tamper-resistant/evident containerconstructed in accordance with a preferred embodiment of the subjectinvention and designated generally by reference numeral 310. Container310 is generally round in shape, but may be formed in other shapes, andhas similar features to containers 10, 110 and 210 described above.Container 310 includes, among other things, a base portion 314 and acover portion 312 joined together by an integrally formed hinge 316 thatdefines a tamper-evident frangible pull strip 318, which must be removedbefore cover portion 312 can be readily removed from base portion 314.An upwardly projecting bead 334 is disposed on peripheral rim 322 ofbase portion 314. Bead 334 is positioned to substantially surround theouter edge of flange 324 of cover portion 312 when container 310 isclosed, thus physically blocking access by fingers or any other objectthat could be applied to the edge of peripheral flange 324 and rim 322for leverage while attempting to pry cover portion 312 from base portion314.

In this embodiment, a plurality of supporting gussets 362 a-h, eachextending from about the enclosed bottom of base portion 314 to aboutextending rim 332 are disposed proximate the eight corners of baseportion 314 to provide enhanced structural integrity. Gussets 362 alsodefine interior spaces 363 that can be used to facilitate fingers of auser to remove an object (such as a pie, for example) from container310. Container 310 can also be provided with lower and upper vents 364,365 respectively, disposed circumferentially proximate the top andbottom of the container 310 to facilitate defrosting or heating of thecontents of container 310. In the case of a frozen pie, for example,warm air can be drawn in through upper vents 365. As air enters throughupper vent 365, it is cooled, and sinks out through lower vent 364. Ifdesired, vents 364 can be positioned proximate the lower portions ofgussets 362, whereby each gusset can act as an air duct to facilitatetransport of air through the container. It will be appreciated thatvents 364, 365 can also operate to cool the contents of container 310,whereby relatively cool ambient air can be drawn in through lower ducts364 and out of upper ducts 365, whereby the air is heated by thecontents of the container to drive the flow. It will be appreciated thatthe location of vents 364, 365 can be varied, as desired. As depicted,vents 365 are disposed in welled recesses that form ribs 372 in coverportion 312 of container 310.

It was discovered through experimentation that it is desirable to havegussets 362 extend as close to the bottom 317 of base 314 as possible.This spreads out the load of the contents of container 310 over a largerarea of containers 310 when containers 310 are stacked. It has also beendiscovered that it is desirable to have gussets 362 extend up to flange375 to prevent flexure of container 310 to prevent flange 324 from beingseparated from bead 334. These design features significantly help makecontainer 310 more tamper resistant by making container 310 moreresistant to flexure.

As depicted, bottom 317 of base 314 is generally octagonal, and isadapted and configured to nest within the octagonal recess 312 a formedin cover portion 312. The octagonal features permit directional stackingwhich can facilitate the alignment, transport, display and merchandizingof goods. It will be understood that other shapes besides octagonal canbe used, as understood by those of skill in the art.

As depicted in FIG. 27, gussets 362 are adapted and configured so thatgussets 362 can act as guides for guiding container between parallelrails (the locations of which being represented by axes X) of a guidingdevice to move, stack, fill and/or close containers 310, if desired.

As further disclosed in this embodiment, a circumferential engagementsealing interface between cover portion 312 and base portion 314 isdefined in part by a rounded segment 390, a relatively straight segment392 and two rounded corner portions 394. The shape of interface isadapted and configured to provide substantial resistance to ensurecontainer 310 is relatively tamper resistant.

Container 310 also includes an additional independent, engagingmechanism that provides even further structural integrity, enhancessecurity by urging flange 324 to remain in position against peripheralrim 322, and facilitates the reattachment of cover portion 312 to baseportion 314, among other things. A plurality of male engaging members368 project upwardly from base portion 314 disposed circumferentiallyabout container 310. Male engaging members 368 actually cooperate tourge flange 324 against peripheral rim 322. This advantageously helpsprevent tampering with the container. Members 368 also facilitate inguiding and aligning cover portion 312 with base portion to facilitatethe reclosing of container 310 after it has been opened.

It will be understood that the cover portions 12, 112, 212 and 312 andbase portions 14, 114, 214 and 314 can be made of different coloredmaterials. For example, all or a part of the cover portions and/or baseportions can be transparent while the rest of the container can betranslucent or opaque. In accordance with one embodiment, two-tonesheeting is used (such as PET) wherein a dark opaque material is matedadjacently to a transparent segment. The separation between the twosections can be routed in the machine direction of the thermoformingmachine used to make the containers. The transition area fromtransparent to opaque can be aligned with the tamper evident strip ofthe container so that the cover portion can be a different color than(or transparent or translucent compared to) the base portion.

Although exemplary and preferred aspects and embodiments of the presentinvention and forming methods have been described with a full set offeatures, it is to be understood that the disclosed container and methodof manufacture may be practiced successfully without the incorporationof each of those features. The scope of the present invention is notlimited only to the tamper-resistant/evident containers and methods ofmanufacture disclosed herein. Thus, it is to be understood thatmodifications and variations may be utilized without departure from thespirit and scope of the invention and method disclosed herein, as thoseskilled in the art will readily understand. Such modifications andvariations are considered to be within the purview and scope of theappended claims and their equivalents.

1. A method of forming a tamper-resistant/evident container comprising:a) providing a sheet of plastic material that is at least partiallytransparent; b) forming a cover portion at least in part from the sheetof plastic material, wherein the cover portion forming step includesforming an outwardly extending peripheral flange; b) forming a baseportion including an upper peripheral edge from the sheet of plasticmaterial; c) forming a hinge joining the cover portion with the baseportion joining the cover portion and base portion; and d) forming afrangible tear strip defined by forming a plurality of lines ofweakness, wherein the tear strip is formed along at least one edge ofthe container proximate a region where the cover portion and baseportion meet, and wherein the tear strip is formed in a manner that whenthe tear strip is severed, a projection is provided extending from atleast one of the base portion and cover portion for facilitating removalof the cover portion from the base portion to open the container, andwherein the cover portion, base portion, hinge and tear strip areunitarily formed.
 2. The method of claim 1, wherein the container isformed from a material including at least one of polyethyleneterephthalate, polyethylene, polypropylene and polyvinyl chloride. 3.The method of claim 1, wherein the container is formed from a roll ofpolyethylene terephthalate subjected to a vacuum and pressure mold withplug assist.
 4. The method of claim 1, wherein the frangible tear stripis formed when the cover portion and base portion are formed.
 5. Themethod of claim 1, wherein the frangible tear strip is formed after thecover portion and base portion are formed.
 6. The method of claim 5,wherein the container is indexed to a station where one or more knivesliberate the container and create the tear strip.
 7. The method of claim5, wherein the tear strip is formed by an intermittent cutter.
 8. Themethod of claim 5, wherein the tear strip is formed by a progressivepunch and die operation.
 9. The method of claim 5, wherein the tearstrip is formed by a numerically controlled laser.
 10. The method ofclaim 5, wherein the tear strip is formed by an electro-mechanicalsystem.
 11. The method of claim 5, wherein the tear strip is formed byan ultra sonic system.
 12. The method of claim 5, wherein the tear stripis formed by a hydrodynamic system.
 13. The method of claim 1, furthercomprising forming vents in the container to promote airflowtherethrough.
 14. The method of claim 1, further comprising forming afirst portion of a latch on a periphery of the base portion to projecttoward the cover portion when the container is closed.
 15. The method ofclaim 14, further comprising forming a second portion of the latch on aperiphery of the cover portion to correspond to the position of thefirst portion of the latch when the container is closed, such that thefirst and second portions of the latch engage to form a non-permanentengagement when the container is closed.
 16. The method of claim 1,wherein the sheet of plastic material is two-tone sheeting having afirst non-transparent segment mated adjacently to a second segment thatis transparent, wherein the two segments meet at a transition area. 17.The method of claim 16, wherein the non-transparent segment includesopaque material.
 18. The method of claim 16, wherein the container isformed by routing the sheet of plastic material through a thermoformingmachine, wherein the transition area is aligned with to a machinedirection of the thermoforming machine.
 19. The method of claim 18,wherein the transition area from transparent to non-transparent materialis aligned with the frangible tear strip of the container so that thecover portion is made from different material from the base portion. 20.The method of claim 1, wherein the sheet of plastic material is two-tonesheeting having a first non-translucent segment mated adjacently to asecond segment that is translucent, wherein the two segments meet at atransition area.
 21. A method of forming a tamper-resistant/evidentcontainer comprising: a) providing a container formed from a sheet ofplastic material that is at least partially transparent, the containerincluding: i) a cover portion formed at least in part from the sheet ofplastic material, wherein the cover portion includes forming anoutwardly extending peripheral flange; ii) a base portion including anupper peripheral edge formed from the sheet of plastic material; iii) ahinge joining the cover portion with the base portion; and b) forming afrangible tear strip defined by forming a plurality of lines ofweakness, wherein the tear strip is formed along at least one edge ofthe container proximate a region where the cover portion and baseportion meet, and wherein the tear strip is formed in a manner that whenthe tear strip is severed, a projection is provided extending from atleast one of the base portion and cover portion for facilitating removalof the cover portion from the base portion to open the container, andwherein the cover portion, base portion, hinge and tear strip areunitarily formed.